System and method to adhere a pouch to an insert

ABSTRACT

A container for distributing product samples comprises material configured to form a pocket. A layer of clean release adhesive is disposed on the first external face of the pocket. A first surface of a film is placed adjacent to the layer of clean release adhesive such that the first surface of the film and the first external face of the pocket are releasably attached. A layer of permanent adhesive disposed on a second surface of the film. A surface of a liner is placed adjacent to the permanent adhesive such that the permanent adhesive is exposed if the liner is removed. A product sample may be sealed in a pocket formed from the material.

BACKGROUND

1. Field of Invention

The present invention relates generally to distribution of product samples and more specifically to a container that can be adhered to a paper sheet.

2. Description of Related Art

Presently, product samples are often distributed in packets attached to a paper sheet, such as a magazine insert, using 100% solid hot melt glue (“booger glue”). A line of booger glue is applied to the back of the packet or to an insert and adheres the packet to the insert. While the packet is securely adhered to the paper, when the packet is removed, the rubbery, sticky, booger glue remains on the packet or on the insert. The booger glue may leave a stain on the insert when removed. Further, if the insert is a page in a magazine, the magazine page may adhere to the opposite page if the magazine is closed. Further, because booger glue does not cause fiber tear when the packet is removed, U.S. Post Office regulations subject publications including booger-glued packets to higher postage rates.

Product samples may additionally be distributed using product wells, such as those distributed by Arcade. Product wells comprise a product sample mixed with inert gas sealed between two layers of foil glued onto an insert. The top layer can be peeled off of the bottom layer to expose the product sample. The bottom layer forming the well causes fiber tear when removed from the page, and therefore does not subject the publication to higher postage rates. The wells, however, result in exposed product that can rub off on other objects that the wells come in contact with including furniture, clothing, and the opposite page of a magazine.

Therefore, there is a need for a way to attach a product sample to an insert such that the product sample can be removed cleanly from the insert, while allowing the attachment to cause fiber tear when removed.

SUMMARY

A container for product samples and a method for assembling the same is provided. A container for distributing product samples comprises a sheet of material configured to form a pocket, the pocket having a first external face and a second external face. Disposed on the first external face is a layer of clean release adhesive, the layer of clean-release adhesive having a width approximately equal to a width of the first external face of the pocket. A first surface of a film is adjacent to the layer of clean release adhesive such that the first surface of the film and the first external face of the pocket are releasably attached. The film has a width approximately equal to the width of the first external face of the pocket. A layer of permanent adhesive having a width approximately equal to a width of the film is disposed on a second surface of the film. Adjacent to the permanent adhesive is a liner such that the permanent adhesive is exposed if the liner is removed.

A method for generating a sample pouch comprises providing a sheet of material configured to form a pocket having a first external face and a second external face. A clean release adhesive is applied to a portion of the material corresponding to the first external face. The top side of a film having a top side and a bottom side is placed adjacent to the clean release adhesive such that the first face of the pocket is releasably attached to the top side of the film. A permanent adhesive is applied to the bottom side of the film. The permanent adhesive does not permanently adhere to a liner provided. The liner is placed adjacent to the permanent adhesive such that the bottom side of the film is releasably attached to the liner. The material is formed into the pocket, and the product sample is sealed in the pocket.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts exemplary material that may used to form a plurality of pouches according to various embodiments;

FIG. 2 depicts a cross-section of the material including the attachment means according to various embodiments;

FIG. 3 depicts a cross-section of the formed pouch and the attachment means according to various embodiments;

FIG. 4 is a flowchart with the major steps for assembling the pouch with the attachment means according to various embodiments; and

FIG. 5 depicts a diagram of an exemplary paper sheet with the pouch attached according to various embodiments.

DETAILED DESCRIPTION

A container and method of assembly of a container for distributing a product sample are provided. The container comprises a foil pouch and attachment means for attaching the pouch to a paper sheet such as a magazine, postcard, flier, or the like. A clean release adhesive allows a consumer to remove the pouch from the paper sheet without leaving exposed glue that sticks to an opposite page of other objects. A film permanently adhered to the paper sheet protects the sheet from staining and/or tearing as the pouch is removed. Additionally, removal of the pouch does not leave an exposed product sample on the paper sheet.

The method of assembly comprises providing a sheet of material configured to form a pocket having a first external face and a second external face and applying attachment means to a portion of the material corresponding to the first external face. The material is formed into the pocket and sealed with the product sample inside. The method of assembly allows for the use of equipment that is commonly used. Further, because the pocket is not formed until after the attachment means are applied, the attachment means can be applied to a larger portion of the first external face, resulting in a more secure attachment to the paper sheet.

FIG. 1 depicts an exterior surface of exemplary material 100 that may be used to form a plurality of pouches according to various embodiments. The exemplary material 100 may be used to form a welded pouch or a peelable pouch. The material 100 may comprise a sheet having a plurality of back faces 102, front faces 104, partition lines 106, and a fold line 108.

The material 100 comprises an interior surface (not shown) that is substantially impervious to liquids. The material 100 may comprise a sealant layer, a barrier layer, and an outside printability layer. The sealant layer, forming the interior surface, may be a plastic that seals with itself to form the pouch. In embodiments comprising a welded pouch, the sealant layer may form a seal with or without an adhesive in the presence of heat, pressure, or the like. In embodiments comprising a peelable pouch, the sealant layer may comprise Dupont Surlyn, Dupont Nucrel, polyolefin and vinyl acetate blends, or the like.

The barrier layer provides opacity and strength to the pouch. The barrier layer is substantially impervious to air, liquid or other materials within the pouch. The barrier layer may be constructed using vinyl, foil, metallized polyester, or the like. The outside printability layer is a film, such as polyester, on which text and/or graphics are printed or reverse-printed. Persons skilled in the art will recognize additional layers and/or materials that may be used to form the pouch.

Each pouch may comprise a front face 104 and a back face 102, which may include printed text and/or images. In typical pouches, the back faces 102 may include information such as product description, directions for use, ingredients, warnings, and the like. The front faces 104 may typically include an eye-catching graphic or logo. The front faces 104 and the back faces 102 may be of any size or dimension. The back faces 102 and the front faces 104 may be the same size, as shown. In some embodiments, the front faces 104 and the back faces 102 may be switched.

The partition lines 106 separate the faces of one packet from the faces of another, and thus indicate where a first pouch ends and a second pouch begins. In some embodiments, the partition lines 106 are not printed on the material 100. During assembly, the pouches may be sealed and separated along the partition lines 106.

The fold line 108 indicates where the material 100 is folded along a straight line to form the pouch. In the embodiment shown, the fold line 108 approximately bisects the material 100. To form the pocket, the material 100 may be folded so the back side of the back face 102 is adjacent to the front side of the front face 104, for example, in the direction of arrow 110. In other embodiments, the material 100 may be folded in the opposite direction. In additional embodiments, the material 100 may include additional alignment markings printed on the back faces 102 and/or the front faces 104.

FIG. 2 depicts a cross-section 200 of the material 100 including the attachment means according to various embodiments. The attachment means comprise layers of material as well as adhesives that can be used to attach the material 100 to a paper sheet. Material 100 is shown here with the printed (top) side down. Front face 104 is to the left of fold line 108 and back face 102 is to the right. The attachment means are adhered to the back face 102 of the material 100 such that if the material 100 is folded at fold line 108 in the direction of arrow 110, the front face 104 is face-up if the pouch is adhered to a paper sheet. The attachment means may have the same width as the back face 102 or a substantial portion of the width of the back face 102.

The clean release adhesive layer 202 comprises a clean release adhesive. Clean release adhesives are also known in the art as breakaway adhesives or fugitive adhesives. The clean release adhesive is selected such that if the material 100 is removed, the back face 102 is substantially free of film or adhesive residue and thus nonadhesive. The clean release adhesive layer 202 may be applied within a substantial area of the back face 102. In one embodiment, the clean release adhesive layer 202 is applied to substantially all of the back face 102.

The film 204 comprises a thin film attached to the back face 104 via the clean release adhesive layer 202. The film 204 may comprise a polyolefin or plastic film such as polyester, polypropylene, or polystyrene. The film 204 may be transparent, opaque, or printed. The top surface of the film 204 is in contact with the clean release adhesive layer 202 when the material 100 is attached. Like the back face 102, if the material 100 is removed, the film 204 is substantially free of adhesive residue and again nonadhesive. The film 204 may have substantially the same width as the back face 102. In other embodiments, the film 204 may have a smaller or larger width than that of the back face 102. The film 204 has two opposite sides which may be referred to as the “top side” and the “bottom side.”

The permanent adhesive layer 206 comprises a permanent adhesive. The permanent adhesive may be rubber-based, acrylic, polyurethane (PUR), or the like. The permanent adhesive may be 100% solid, water-based, or solvent-based.

The permanent adhesive layer 206 is able to form a permanent bond between the film 204 and a paper sheet (not shown) or insert. The permanent adhesive layer 206 permanently bonds to the film when applied. The permanent adhesive layer 206 may be applied across a substantial portion of the width of the film 204. In some embodiments, the permanent adhesive layer 206 is applied across the entire width of the film 204.

The liner 208 is applied to the permanent adhesive layer 208 to prevent the permanent adhesive from bonding to other materials prior to application to the paper sheet. The liner 208 is at least as wide as the permanent adhesive layer 206 applied to the film 204. The liner 208 is selected such that it is releasably attached to the film 204 when placed in contact with the permanent adhesive layer 206. The liner 208 may comprise a polyolefin or plastic film such as polyester, polypropylene, or polystyrene, and may be clear, opaque, or printed. The liner 208 may be selected based on the permanent adhesive used such that the liner 208 is substantially free of film or adhesive residue when released. Further, the liner 208 may be nonadhesive upon being removed from the permanent adhesive layer 206. The liner 208 may be removable by a label applicator.

FIG. 3 depicts a cross-section 300 of the formed pouch and the attachment means according to various embodiments. The pouch 302 may formed by folding the material 100 along a straight line. In the shown embodiment, the material 100 is folded substantially in half such that the front face 104 of material 100 forms the top surface of a pocket 304, and the back face 102 of material 100 forms the bottom surface of the pocket 304. The pocket 304 may be filled with a liquid, oil, and/or a solid, for example, lotion, perfume, cake frosting, medicinal tablets, or the like. The pocket 304 may be welded or peelable. The attachment means 202-208 are as discussed above with reference to FIG. 2. The pouch 302 and the attachment means may be applied to a paper sheet using a label applicator.

FIG. 4 is a flowchart 400 with the major steps for assembling the pouch with the attachment means according to various embodiments. The steps may be performed by machines such as label applicators.

In step 402, material used to create a pouch is provided. The material may be, for example, material 100 as described herein. The material may form a welded pouch or a peelable pouch.

In step 404, a clean release adhesive is applied to at least a portion of the material corresponding to the back face of the pouch. In some embodiments, the clean release adhesive may be applied in a pattern on the back face.

In step 406, a film, such as film 204, is provided. In step 408, the top side of the film is placed in contact with the clean release adhesive such that the back face is releasably attached to the top side of the film.

In step 410, a permanent adhesive is applied to the bottom side of the film. In step 412, a liner is provided. In step 414, the liner is placed in contact with the permanent adhesive such that the permanent adhesive is not exposed.

In step 416, the material is formed to create a pocket. The pocket may be created by folding the material along a straight line. In step 418, the product sample is sealed in the pocket. The pocket may be sealed by welding the sides of the pocket or by creating a peelable pouch.

In step 420, the liner is removed to expose the permanent adhesive. In step 422, a paper sheet is placed in contact with the permanent adhesive to adhere the sealed pocket to the paper sheet. The paper sheet may comprise an insert, a postcard, a magazine page, or the like.

The steps described may be performed in other orders or substantially spontaneously. For example, the film and the liner may be adhered using the permanent adhesive and subsequently the film and the liner applied to the material as a unit using the clean release adhesive. In other embodiments, the pouch may be formed and sealed prior to applying the attachment means.

FIG. 5 depicts a diagram of an exemplary paper sheet 502 with the pouch 302 attached according to various embodiments. Sheet 502 comprises any paper sheet to which the pouch 302 can be attached. The pouch 302 comprises any pouch and as described herein. The pouch 302 may be any size relative to the sheet 502. As shown, the front face 104 is visible while the pouch 302 is attached to the sheet 502.

If the pouch 302 is removed, the film 204 remains adhered to the sheet 502. Because the pouch 302 may be adhered to the film using a clean release adhesive, the back face 102 becomes substantially non-adhesive when no longer in contact with the film 204. Similarly, the top side of the film 204 can also be nonadhesive when the back face 102 is removed. Thus, the top side of the film 204 may not cause pages to stick to the sheet 502.

As shown, the film 204 is transparent but in other embodiments, the film 204 may be opaque or printed. The film 204 is permanently adhered to the sheet 502. In some embodiments, if the film 204 is removed from the sheet 502, the permanent adhesive causes fiber tear of the sheet 502.

In the foregoing specification, the present invention is described with reference to specific embodiments thereof, but those skilled in the art will recognize that the present invention is not limited thereto. Various features and aspects of the above-described present invention may be used individually or jointly. Further, the present invention can be utilized in any number of environments and applications beyond those described herein without departing from the broader spirit and scope of the specification. The specification and drawings are, accordingly, to be regarded as illustrative rather than restrictive. It will be recognized that the terms “comprising,” “including,” and “having,” as used herein, are specifically intended to be read as open-ended terms of art. 

1. A container for distributing product samples comprising: a sheet configured to form a pocket, the pocket having a first external face and a second external face; a layer of clean release adhesive disposed on the first external face of the pocket; a film approximately as wide as the first external face of the pocket, and having a first surface and a second surface, the first surface adjacent to the layer of clean release adhesive such that the first surface of the film and the first external face of the pocket are releasably attached; a layer of permanent adhesive disposed on the second surface of the film, and having a width approximately equal to a width of the film; and a liner having a surface adjacent to the permanent adhesive such that the permanent adhesive is exposed if the liner is removed.
 2. The container of claim 1, wherein the pocket contains a product sample.
 3. The container of claim 2, wherein the pocket is welded.
 4. The container of claim 2, wherein the pocket is peelable.
 5. The container of claim 2, wherein the layer of clean-release adhesive has a width approximately equal to a width of the first external face of the pocket.
 6. The container of claim 1, wherein the material is substantially folded along a straight line to form the pocket.
 7. The container of claim 1, wherein the clean release adhesive layer becomes non-adhesive if the material is removed from the film.
 8. The container of claim 1, wherein the permanent adhesive bonds to paper such that the paper sustains fiber tear if the film is sought to be separated from the paper.
 9. The container of claim 1, wherein the permanent adhesive comprises rubber polyurethane.
 10. The container of claim 1, wherein the permanent adhesive comprises acrylic polyurethane.
 11. The container of claim 1, wherein the film comprises a polyolefin.
 12. The container of claim 1, wherein the film is transparent.
 13. A method for generating a sample pouch comprising: providing a sheet of material configured to form a pocket having a first external face and a second external face; applying a clean release adhesive to a portion of the material corresponding to the first external face; providing a film having a top side and a bottom side; placing the top side of the film adjacent to the clean release adhesive such that the first face of the pocket is releasably attached to the top side of the film; applying a permanent adhesive to the bottom side of the film; providing a liner to which the permanent adhesive does not adhere; placing the liner adjacent to the permanent adhesive such that the bottom side of the film is releasably attached to the liner; forming the material into the pocket; and sealing the product sample in the pocket.
 14. The method of claim 13, further comprising: removing the liner; and placing a paper adjacent to the permanent adhesive such that the bottom side of the film is permanently attached to the paper.
 15. The method of claim 14, wherein the paper undergoes fiber tear if the film is removed from the paper.
 16. The method of claim 13, wherein forming the material into the pocket is performed by folding the material along a straight line.
 17. The method of claim 13, wherein the first surface of the film is nonadhesive if the pouch material is removed.
 18. A container for distributing product samples comprising: a sheet configured to form a pocket, the pocket having a first external face and a second external face; a first layer of adhesive disposed on the first external face of the pocket, the first layer of the adhesive having a width approximately equal to a width of the first external face of the pocket; a film having a width approximately equal to the width of the first external face of the pocket, a first surface, and a second surface, the first surface adjacent to the first layer of adhesive such that the first surface of the film and the first external face of the pocket are releasably attached; a second layer of adhesive disposed on the second surface of the film, the second layer of adhesive having a width approximately equal to a width of the film; and a liner having a surface adjacent to the permanent adhesive such that the second layer of adhesive is exposed if the liner is removed.
 19. The container of claim 18, wherein the first layer of adhesive comprises a clean release glue which becomes nonadhesive if the material is removed from the film.
 20. The container of claim 18, wherein the second layer of adhesive comprises a permanent adhesive.
 21. The container of claim 18, wherein the film comprises a plastic film.
 22. The container of claim 18, wherein the second layer of adhesive bonds to paper such that the paper sustains fiber tear if the film is sought to be separated from the paper. 